Full segment configuration introduction and schematic diagram
Process Flow: ① Pre-accumulation book-feeding device → ② Book separating device → ③ Buffer queue conveyor → ④ Self-dropping book conveyor → ⑤ Dual servo hydraulic pre-pressing device → ⑥ Dual-liner glue and backing integrated machine → ⑦ Dual-channel swing-head book separating device → ⑧ Dual-channel drying (6 meters) → ⑨ Dual-channel turning line → ⑩ Dual-channel drying (3 meters) → ⑪ Dual-channel post-press shaping → ⑫ Book block inverting and flipping machine → ⑬ Conveyor line (can be connected with three-side cutting machine)
Equipment Highlights: Automatic plate change (one-key plate change for all machines from pre-press to post-press), no queue needed for products, unaffected by broken or empty books, production possible for just a few or dozens of books! Realizes an intelligent digital linkage production line!
2. Sectional Introduction and Parameters
2.1 Book Distribution by Machine, Three-Stage Hydraulic Shaping
(1) Hydraulic station control system driven by dual servomotors, providing precise pressure control.
(2) Pre-press shaping mechanism with a maximum pressure of 40 tons, meeting the shaping requirements for various types of books.
(3) Equipped with vibration and push rods to ensure books are neatly arranged.(4) Three-plate step-by-step shaping mechanism, ensuring perfect shaping of all parts of the books.
| ZC-FF420 | ZC-SS508 Conveyor Line (Can Replace FF420 Manual Book Placement) ZC-S50 | ZC-QY460 |
| Machine size | 2745*1485*1468(mm) | Machine size | 1610*758*908(mm)SS508 2343*1500*783(mm)S50 | Machine size | 3660*1510*1360(mm) |
Power supply | 380 v | Power supply | AC220V | Power supply | AC380V |
| Power | 1.0 KW | Power | 0.5KW | Power | 4KW |
| Weight | 450KG | Power ... | 5000KG | Power ... | 3500KG |
| Production size | A6-A3 | Production size | A6-A3 | Production size | A6-A3 |
| Production thickness | 2-30mm | Production thickness | 5-80mm | Production thickness | 5-80mm |
| At the fastest speed | 5000pcs/H | At the fastest speed | 3000pcs/H | At the fastest speed | 3000pcs/H |
2.2 Double-linen Laminated Back Packaging All-in-One Machine
| Machine size | 8979*1575*1750(mm) |
| Power supply | AC380V |
| Power | 6KW |
| Weight | 4000KG |
| Production size | A6-A3 |
| Production thickness | 5-80mm |
| At the fastest speed | 2000pcs/H |
B60 Introduction
(1) The all-in-one machine applies glue to both endpapers, changing the traditional brushing method (where glue is brushed on the side of the book block, making excess glue difficult to clean, glue sticking to the track, and uneven glue application). In this machine, the endpaper glue is brushed on the inner side of the endpaper, synchronously bonding with the book block.
(2) The gluing method can be optionally configured with cold glue or hot glue. Apply white glue twice: after a small amount of glue is applied the first time, it is cured by infrared drying to form a glue film that prevents glue from seeping into the needle holes; the second application of glue creates a more robust coating. The mechanical gluing position then completes the side-gluing of the book block backing paper, with the grain-direction jumbo roll paper synchronously completing the book block backing process (particularly suitable for round-backed books and also saves paper change time). The second layer of base glue can be replaced with a hot glue system (for applying hot glue to the spine of thin book blocks).
(3) All glue tanks are equipped with an automatic glue extraction system. The drying system uses gold-plated tungsten heating tubes, stone-like insulation boards, and automatic water circulation insulation.
(4) The main coil-gluing machine has an anti-lock chain (other models do not, and jamming is very troublesome), which can be easily unlocked. The conveyor chain of the coil-gluing and spine-pasting main machine uses a high-precision corner machine (other models do not have this, or only a small one). The chain track and key parts are equipped with automatic lubrication devices (other models do not have this). The minimum exposed height of the book block when conveyed and clamped is 32mm (lower than most on the market, resulting in better glue application), and multiple spring blocks assist in clamping the spine. This is very helpful for glue application on hardcover books with heavy ink, Bibles, dictionaries, and other similar books, preventing issues such as book sticking, pinhole glue seepage, spine tilt, and wrinkling.
(5) Binding Method: Grain-aligned large roll paper, suitable for all hardcover books and notebooks with round or square spines, especially for rounded hardcover: even curvature, shaped without rebound, ideal for dictionaries, Bibles, genealogies, and premium publications. The large roll spine strip paper is cross-cut, reducing the frequency of replacing spine strips and changing the grain direction of the strips. Grain-aligned binding can produce 40 books per minute, a speed that surpasses all similar devices on the market; small roll paper binding is suitable for notebooks, hardcover books, and similar publications, with an even faster speed, reaching up to 60 books per minute.
(6) Dual-channel rotary book separator: Books are diverted into the drying channel.
2.3 Dual-channel drying
Adopting a dual-channel drying system with a dual-channel turning design, it integrates a 6-meter main drying section and a 3-meter auxiliary drying section to ensure the book spine is thoroughly dried. The optimized turning structure improves the overall machine layout, reduces the footprint, shortens the operator's movement range, and enhances efficiency. Furthermore, the books are turned without forced mechanical conveyance; they smoothly follow the conveyor belt during turns, preventing wrinkling or other issues. The entire line is centrally controlled by a unified system, enabling automated operation without manual size adjustments.
| ZC-R60 | ZC-W2400 | ZC-R30 |
| Machine size | 6000*780*1320(mm) | Machine size | 2400*780*1320(mm) | Machine size | 3000*780*1320(mm） |
| Power supply | AC380V | Power supply | AC380V | Power supply | AC380V |
| Power | 6KW | Power | 1.5KW | Power | 6KW |
| Weight | 600KG | Weight | 400KG | Weight | 420KG |
| Production size | A6-A4 | Production size | A6-A4 | Production size | A6-A4 |
| Production thickness | 2-80mm | Production thickness | 2-80mm | Production thickness | A6-A4 |
| At the fastest speed | 4000pcs/H | At the fastest speed | 4000pcs/H | At the fastest speed | 4000pcs/H |
2.4 Dual-Channel Servo Pneumatic Back Pressure
Using a dual-channel synchronous pressing design, the system integrates a servo-driven belt conveyor with a servo book-pushing positioning system to achieve automated and efficient post-press flattening of books. The system can accurately control the pressure and conveying rhythm, ensuring that books are flattened firmly and their dimensions remain stable.
| ZC-HY550 | ZC-DX800 + ZC-2480 |
| Machine Dimensions | 2175*1780*1450(mm) | Machine Dimensions | 1360*660*1270(mm) ZC-DX 8002490*800*815(mm) ZC-2480 |
| Power supply | AC380V | Power supply | AC220V |
| Power | 1.5KW | Power | 1.0KW |
| Weight | 600KG | Weight | 600KG |
| Production Dimensions | A6-A3 | Production Dimensions | A6-A3 |
| Production Thickness | 2-80mm | Production Thickness | 2-80mm |
| At the fastest speed | 2000-3500pcs/H | At the fastest speed | 2000-3500pcs/H |
3. Workshop Layout Plan
3.1 Layout Plan One
①ZC-SS508 Book Core Queuing Conveyor
②ZC-S50 Front Press Book Core Conveyor
③ZC-QY460 3-Stage Front Press
④ZC-B60 Double-Liner Book Binding Host
⑤ZC-BT60 Book Ejector Swing Arm
⑥ZC-R60 6m Dual-Channel Drying Line
⑦ZC-W2400 Dual-Channel 180°Turning Line
⑧ZC-R30 3m Dual-Channel Drying Line
⑨ZC-HY550 Dual-Channel Rear Press
⑩ZC-DX80 Book Core Gentle Guide Machine
⑪ZC-2400 Book Core Queuing Conveyor
3.2 Layout Plan Two
①ZC-FF420 Stacking Automatic Book Dispenser
②ZC-S50 Front Press Book Core Conveyor
③ZC-QY460B 2-Stage Front Press
④ZC-B60 Double-Liner Book Binding Host
⑤ZC-BT60 Book Ejector Swing Arm
⑥ZC-R60 6m Dual-Channel Drying Line
⑦ZC-W2400 Dual-Channel 180°Turning Line
⑧ZC-R30 3m Dual-Channel Drying Line
⑨ZC-HY550 Dual-Channel Rear Press
⑩ZC-DX80 Book Core Gentle Guide Machine
⑪ZC-2400 Book Core Queuing Conveyor
3.3 Layout Plan Three
①ZC-FF420 Stacking Automatic Book Dispenser
②ZC-S50 Front Press Book Core Conveyor
③ZC-QY460B 2-Stage Front Press
④ZC-B60 Double-Liner Book Binding Host
⑤ZC-BT60 Book Ejector Swing Arm
⑥ZC-R60 6m Dual-Channel Drying Line
⑦ZC-HY550 Dual-Channel Rear Press
⑧ZC-DX80 Book Core Gentle Guide Machine
⑨ZC-2400 Book Core Queuing Conveyor
3.4 Layout Plan 4
①ZC-B60 Double-Liner Book Binding Host
②ZC-BT60 Book Ejector Swing Arm
③ZC-R60 6m Dual-Channel Drying Line
④ZC-HY550 Dual-Channel Rear Press
⑤ZC-DX80 Book Core Gentle Guide Machine
⑥ZC-2400 Book Core Queuing Conveyor
4. Back packaging module and hot/cold adhesive selection
Grain-aligned large roll paper and small roll paper are different modules (can be chosen according to actual needs).
Grain-aligned large roll paper: Especially suitable for round spine hardcover books, with better results for grain-aligned round spine binding. It is also suitable for ordinary square-spine binding of notebooks, books, etc. Large roll paper can save time in replacing the backing paper. This type of backing paper has a complex structure and higher cost, with a maximum speed of 40 books/minute.
Small roll paper: The machine structure is relatively simple, cost is lower, and speed can reach 60 books/minute.
Either of the above can be chosen according to actual needs.
Optional upgrade available: Hot glue module and hot glue oven, for thin hardcover books. The machine module can be easily replaced, swapped at the position of the second cold glue tank.
